Background Information The prior art discloses box erecting machines which are designed for setting up and closing the bottom of so called slit-boxes which are supplied as a collapsed tubularly formed container or carton blank having sides and bottom flaps and top flaps which are integral with the said sides, comprises a support which carries a magazine for the collapsed tube-formed carton blanks, a feeding unit for pulling out and feeding a carton blank and a bottom closing means for folding in and possibly sealing the bottom flaps before the carton is filled. The feeding unit comprises a pneumatically acting catcher which is mounted perpendicularly to the feeding path and it is provided extendable so as to be able to catch a carton blank, pull same out of the magazine and together with the carton blank move along a feeding path while the carton is set up to tube form and the bottom flaps are folded in. At this stage the catcher is disengaged from the carton and

moves back to catch another carton. In such prior art apparatus the feeding forward of the set up and bottom closed carton is made in that the carton is pushed forward by the following carton.

U. S. Patent No. 4,285,679 to Wahle, for example, discloses a box erecting apparatus comprising a support which carries a magazine for carton blanks, a feeder unit and a bottom flap closing means. The feeding unit includes a suction catcher adapted to catch and open a container blank and to move the said blank along a handling path while closing at least bottom thereof. The feeding unit carries on an expelling means having an expellor arm which is moveable between a position inside the handling path and a position outside the handling path and which is mounted at a predetermined distance in front of the feeder unit as considered in the feeding direction. The expellor arm is actuated by a hydraulic or pneumatic cylinder to move to a position inside the handling path when the suction catcher starts to move along the handling path after having pulled a carton blank out of the magazine and to move the expellor arm out of the handling path after the suction catcher with the expellor arm and the set up carton has reached a predetermined end position and just before the suction catcher starts to return to its initial position in contact with the foremost carton blank of the magazine.

The prior art also discloses a number of such box assembly machines in which such machines are integrated with devices for delivering a product to be packed into such boxes at a packaging point positioned at the output of the box assembly machine. Such integrated box erecting

machines and product delivery systems have, however, disadvantages in that they do not always allow for and easy, efficient and cost effective packing of the boxes at the packaging station.

In particular, prior art box erecting machines often require considerable interaction between such machines and their human operators. Such human-machine interaction desirably takes into account such ergonomic factors as differences of the physical dimensions and characteristics of the various operators who might be expected to operate the machine, the minimization of operator workload, production of environmental stress, the enhancement of operator safety, and easy access by the operator to displays and controls. A need, therefore, exists to optimize such ergonomic factors in integrated box erecting machines and product delivery apparatus.

Another disadvantage of such integrated box erecting machines and product delivery systems is that they tend to take up a considerable amount of floor space in buildings which they are used. A need, therefore, exists for such an integrated box assembly machine and product delivery system which is efficient and compact with respect to the amount of floor space necessary for it to be used.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an integrated box assembly machine and product delivery system which facilitates easy, efficient and cost effective packaging of products in boxes being assembled.

It is a further object of the present invention to provide an integrated box erecting machine and product delivery system which is adaptable to being adjusted to accommodate different physical dimensions and physical characteristics of the various operators who might be expected to operate the machine.

It is a further object of the present invention to provide an integrated box erecting machine and product delivery system which is adapted to minimizing operator work load.

It is a further object of the present invention to provide an integrated box erecting machine and product delivery system which optimizes other ergonomic factors such as easy access to displays and controls, reduced environmental stress, and a high degree of safety.

It is a still further object of the present invention to provide an integrated box assembly machine and product delivery system which is efficient and cost effective in terms of the amount of floor space which must be devoted to its use.

These and other objects and advantages will be apparent from the present invention which is a method for packaging a product in which a box erecting machine having a frame, a box magazine adjustably and a box folding apparatus mounted on the frame is used with, a box conveyor for receiving boxes from the box erecting machine. Boxes are continuously delivered from this box erecting machine to a packaging station, and there is a product conveyor for also continuously delivering product to the packaging station. Product is continuously removed from the product

conveyor and continuously packed in one of the boxes. An operator is positioned adjacent the box conveyor at the packing station, and the product conveyor is positioned at a greater lateral distance from the operator than the box conveyor. The product conveyor is also positioned above the box conveyor. There is a floor on which the box conveyor and product conveyor are mounted and the box conveyor has a height over the floor surface and the product conveyor has a height over said floor, and the height of the box conveyor and the height of the product conveyor adjusted.

The boxes may be called, and the operator controls calling the boxes.

Each box is processed in a cycle and control is maintained over each box during the entire cycle so that movement by the operator is minimized.

Preferably box dimensions are adjustable, and the tops of the boxes are aligned with the product conveyor.

Also encompassed by the present invention is an apparatus for packaging a product comprising a box erecting machine having a frame.

There is a box magazine adjustably mounted on the frame and a box folding apparatus mounted on the frame, a box conveyor for continuously receiving boxes from the box erecting machine which continuously delivers the boxes to a packaging station. A product conveyor continuously delivers a product to the packaging station. The product conveyor is positioned above the box conveyor and laterally away from the box conveyor relative to the operator.

The box conveyor and product conveyor are parallel and are preferably perpendicular to the magazine.

BRIEF DESCRIPTION OF THE DRAWINGS The preferred embodiment of the invention, illustrative of the best mode in which applicant contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

Fig. 1 is a top plan view of an assembly representing a preferred embodiment of the assembly of the present invention; Fig. 2 is an end view of the assembly in Fig. 1 taken from 22 in Fig.

1; and Fig. 3 is a top plan view of an assembly representing an alternate preferred embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to Figs. 1 and 2, the integrated box assembly machine and product feed system includes a support 10. A magazine 12 extends laterally from the support 10, whereas the box feeder unit shown generally at numeral 14 is aligned with the support 10. The magazine 12 is essentially conventional and includes a carrier 16 and a guide 18. In opposed relation to the magazine 12, there is a suction catcher 20 for folded boxes received from the magazine 12. The feeder unit 14 is also essentially conventional and includes a suction catcher 20 on air piston unit 22 for seizing the first carton blank form the magazine. A support bar 24 is adjustable to accommodate different sizes of boxes and which connects to a fold in device 26 and a rotatable wing 28 as is conventional. There is also a conventional expeller bar 30 which moves boxes to a bottom closure

apparatus shown generally at 32 which includes bottom guide bars as at bar 34 and sidebars 36 and 38.

At the end of the sidebars 36 and 38, there is a continuous conveyor belt 40 which is moved by rollers 42 and 44 which move the assembled boxes in the direction of the arrow to a box packaging position 46 in front of an operator 48. After the box packaging position 46, boxes are moved to a box removal apparatus 50 which includes a frame 52 with a central track 54 and a lateral conveyor 56 moved by vertical pulleys 58 and 60 along with another lateral conveyor 62 moved by vertical pulleys 64 and 66. It will be understood that after the box removal apparatus 50, the boxes will be sealed in a conventional sealing apparatus (not shown). A continuous product conveyor belt 68 is moved by roller 70 and another roller (not shown).

Referring particularly to Fig. 2, there is a roller drive motor 72 and a product conveyor support 74 which are positioned on the frame 10. The frame 10 is mounted on height adjustable feet 76 and 78 which are positioned on a floor surface 80. There is a product 82 on the conveyor belt 68 which is packed by the operator 48 into the box 84 at the box packing position 46. It will be appreciated that the product conveyor belt 68 is positioned above and laterally away from the operator 48 with respect to the box conveyor belt 40. Preferably the distance between the product conveyor belt 68 and the box conveyor belt 40 would be from 2 inches to 20 inches. It will be appreciated that the tops of the boxes as at box 84 are approximately aligned with the product conveyor 68. The distance from the

floor surface 80 to the box conveyor belt 40 would be selected by the skilled practitioner, depending on the height of the operator 48, and this height is adjusted to accommodate differences in operator height by means of the height adjustable feet 76 and 78. There is a hand operated control button 86, by means of which the operator 48 can call boxes as at box 84 onto the continuous conveyor belt 40 and to box packaging position 46 to be loaded with the product 82. Control of the speed of the product conveyor belt 68 can also be effected by the operator 48 at control 86. Alternatively, a foot pedal 88 on floor surface 80 can be used to call boxes as at box 84 or control the speed of product conveyor belt 68. The box removal apparatus 50 is also equipped with a hand control button 90 and an adjustment crank 92.

It will be appreciated that the relative positions of the product conveyor belt 68 and the box conveyor belt 40 substantially contributes to the ergonomic advantages of the overall assembly. In particular, the integrated box erecting machine and product delivery apparatus is easily adjustable to accommodate differences in body sizes, particularly in operator height and more particularly in lower body height and femur length and tibia length by adjustment of the feet 76 and 78. Furthermore, operator workload in bringing the product as at product 82 to the box 84 is minimized by the positioning of the product conveyor 68 above the box conveyor 40 at a distance from 2 inches to 20 inches so that the top of each box as at box 84 is approximately aligned with the product conveyor 68. Such workload is also minimized by the positioning of the product conveyor belt 86

transversely away from the box conveyor belt 40 with respect to the operator. By virtue of this positioning of the product conveyor belt 68 above and transversely away from the box conveyor belt 40, with respect to the operator. The operator may with one easy and comfortable inward and downward motion, move the product as at product 82 from the product conveyor belt 68 to the box conveyor belt 40. Such relative positioning of the product conveyor belt 68 and the box conveyor belt 40 with respect to the operator 48 also enhances safety and lowers the chance of operator injury as well as reducing environmental stress to the operator. The ergonomic efficiency of the overall assembly is also enhanced by the convenient access to controls as at hand control button 42 at the approximate level of the box conveyor belt 40 or alternatively by foot pedal 88 located on the floor 80.

It will also be appreciated that the perpendicular positioning of the magazine 12 relative to the product conveyor belt 68 and the box conveyor belt 40 also contributes to the efficient use of floor space in the overall assembly.

Referring to Fig. 3, another embodiment which is ergonomically adapted for use by a left handed operator 148 is shown. The integrated box assembly machine and product feed system includes a support 110. A magazine 112 extends laterally from the support 110, whereas the box feeder unit shown generally at numeral 114 is aligned with the support 110.

The magazine 112 is essentially conventional and includes a carrier 116 and a guide 118. In opposed relation to the magazine 112, there is a

suction catcher 120 for folded boxes received form the magazine 112. The feeder unit 114 is also essentially conventional and includes a suction catcher 120 for seizing the first carton blank from the magazine 112. A support bar 124 is adjustable to accommodate different sizes of boxes and which connects to a fold in device 126 and a rotatable wing 128 as is conventional. There is also a conventional expeller bar 130 which moves boxes to a bottom closure apparatus shown generally at 132 which includes a bottom guide bar 134 and sidebars 136 and 138.

At the end of the sidebars 136 and 138, there is a continuous conveyor belt 140 which is moved by rollers 142 and 144 which move the assembled boxes in the direction of the arrow to a box packaging position 146 in front of an operator 148. After the box packaging position 146, boxes are moved to a box removal apparatus 150 which includes a frame 152 with a central track 154 and a lateral conveyor 156 moved by vertical pulleys 158 and 160 along with another lateral conveyor 162 moved by vertical pulleys 164 and 166. A continuous product conveyor belt 168 is powered by roller 170 and another roller (not shown) in the direction of the arrow.

Like with the first embodiment, the frame in the second embodiment 110 is mounted on height adjustable feet (not shown) which are positioned on a floor surface 180. A product 182 on the conveyor belt 168 is packed by the operator 148 into a box 184 at the box packing position 146. It will be appreciated that the product conveyor belt 168 is positioned above and laterally away from the operator 148 with respect to the box conveyor belt 140. Itwill be appreciated that the relative positions of the product conveyor

belt 168 and the box conveyor belt 140 substantially contributes to the ergonomic advantages of the overall assembly, particularly in this embodiment for a left handed operator 148. The operator will preferably be able to call individual boxes and/or adjust the speed of the box conveyor belt 140 or product conveyor belt 168 by means of a lateral hand operated control button 186 or alternatively a foot pedal (not shown). The box removal apparatus 150 is also equipped with a hand control button 190 and an adjustment crank 192. The boxes will also be sealed in a conventional way after being packed with the product.

It will be appreciated that this second embodiment of the integrated box erecting machine and product delivery apparatus is particularly ergonomically adapted for use by left handed operators. That is, the operator is positioned adjacent the box conveyor belt 148 so that his right hand 190 is adjacent the bottom closure apparatus 132 and the beginning of the boxy conveyor belt 140. Positioned in this way, the operator 148 will be able to operate the hand operated control button 186 and steady the box 184 with his right hand 194 while he would have his left hand 196 free to move product as at 182 into the box 184.

Referring again to Figs. 1 and 2, it will also be understood that for a right handed operator 48, it would be advantageous to position the operator 88 with the operator's left hand 96 adjacent the bottom closure apparatus 32 at the start of the continuous conveyor belt 40. The right hand 94 of the operator 48 would be available to move the product 82 onto the box 84.

It will be appreciated that a box erecting machine and integral

product delivery apparatus and a method for its use has been described which is adapted to accommodate differences in the physical dimensions and characteristics of the various operators expected to operate the machine, which minimizes operator workload, which allows easy access to displays and controls, and which affords a high degree of operating safety and reduced environmental stress. It will also be appreciated that the box erecting machine and integral product delivery apparatus is perpendicularly arranged between the magazine and the rest of the assembly so as to minimize floor space occupied by the assembly.

Accordingly, the improved BOX ERECTING MACHINE WITH INTEGRAL PRODUCT PACKAGING STATION AND METHOD OF USE is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.

Having now described the features, discoveries, and principles of the

invention, the manner in which the BOX ERECTING MACHINE WITH INTEGRAL PRODUCT PACKAGING STATION AND METHOD OF USE is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended claims.